Claims
- 1. An elongated, planar, generally linear electrical inductive component, comprising:
at least one conductor, each conductor defining a unique conductive path; a magnetic core co-linear with all conductors along the entire component length, and completely surrounding all conductors; and an insulator separating each conductor from any other conductor and from the magnetic member; wherein at any location along the length of the component, in cross section the component includes only one conductor for any conductive path.
- 2. The component of claim 1 comprising a single conductor, to accomplish an inductor.
- 3. The component of claim 2, wherein the magnetic core defines a magnetic circuit comprising a gap.
- 4. The component of claim 2, wherein the conductor defines a gap along its entire length, to create two full-length top and bottom halves, to allow for differential thermal expansion.
- 5. The component of claim 2 wherein the insulator is in part accomplished by a space, to reduce the component capacitance.
- 6. The component of claim 1 comprising two conductors, to accomplish a transformer.
- 7. The component of claim 1 comprising three conductors, to accomplish a differential current transformer.
- 8. The component of claim 1 comprising more than two conductors to accomplish a step up or step down transformer with a desired voltage transformation from the input or inputs to the output or outputs.
- 9. The component of claim 1 wherein the magnetic core and all conductors meander through a plurality of turns, to increase the component's effective length.
- 10. The component of claim 9 wherein the meanders are essentially parallel.
- 11. The component of claim 1, wherein the magnetic core comprises a plurality of laminations separated by non-magnetic insulating material, each lamination completely surrounding all of the conductors.
- 12. The component of claim 1, wherein at least one conductor defines a gap along its entire length, to define two full-length top and bottom halves, to allow for differential thermal expansion.
- 13. A method of fabricating the component of claim 1, comprising:
fabricating two essentially identical halves, each defining one half of the component; and mechanically and magnetically coupling together the two halves, to create the component.
- 14. A method of fabricating an elongated, planar, generally linear electrical inductive component by multi-layered fabrication, the component having at least one conductor, each conductor in the component defining a unique conductive path, a magnetic core co-linear with all conductors along the entire component length, and completely surrounding all conductors, and an insulator separating each conductor from any other conductor and all conductors from the magnetic core member, wherein at any location along the length of the component, in cross section the component includes only one conductor for any conductive path, the method comprising:
providing a lower layer of magnetic core material; providing on top of the lower layer of magnetic core material, a bottom insulator layer; providing on top of the bottom insulator the at least one conductor; providing an insulator adjacent to the outside and top of each conductor; providing, spaced to the outside of the at least one conductor and the adjacent insulator, vertical segments of the magnetic core, in contact with the lower layer of magnetic core material; and providing over the upper insulator and in contact with the magnetic core vertical segments, an upper magnetic core material, to complete a magnetic core circuit.
- 15. The method of claim 14 wherein the component comprises a single conductor, to accomplish an inductor.
- 16. The method of claim 15, wherein the magnetic core defines a circuit comprising a gap.
- 17. The method of claim 15, wherein the conductor defines a gap along its entire length, to define two full-length top and bottom halves, to allow for differential thermal expansion.
- 18. The method of claim 15 wherein the insulator is in part accomplished by a space, to reduce the component capacitance.
- 19. The method of claim 14 comprising two conductors, to accomplish a transformer.
- 20. The method of claim 14 comprising three conductors, to accomplish a differential current transformer.
- 21. The method of claim 14 comprising more than two conductors to accomplish a step up or step down transformer with a desired voltage transformation from the input or inputs to the output or outputs.
- 22. The method of claim 14 wherein the magnetic core and all conductors meander through a plurality of turns, to increase the component's effective length.
- 23. The method of claim 14, wherein the magnetic core comprises a plurality of laminations separated by non-magnetic insulating material, each lamination completely surrounding all of the conductors.
- 24. The method of claim 14, wherein at least one conductor defines a gap along its entire length, to create two full-length top and bottom halves, to allow for differential thermal expansion.
- 25. A method of fabricating an elongated, planar, generally linear electrical inductive component by multi-layered fabrication, the component having at least one conductor, each conductor in the component defining a unique conductive path, a magnetic core co-linear with all conductors along the entire component length, and completely surrounding all conductors, and an insulator separating each conductor from any other conductor and all conductors from the magnetic core, wherein at any location along the length of the component, in cross section the component includes only one conductor for any conductive path, the method comprising:
a. fabricating two component halves, each half made by: providing a lower layer of magnetic core material; providing on top of the lower layer of magnetic core material, a bottom insulator layer; providing on top of the bottom insulator layer the at least one conductor; providing an insulator adjacent to the outside of each conductor; providing, spaced to the outside of the at least one conductor and the adjacent insulator, vertical segments of the magnetic core, in contact with the lower layer of magnetic core material; and planarizing the top surface of the construction; and b. mechanically and magnetically coupling together the planarized surfaces of the two halves, to complete the component.
- 26. The method of claim 25 wherein the component comprises a single conductor, to accomplish an inductor.
- 27. The method of claim 26, wherein the magnetic core defines a magnetic circuit comprising a gap.
- 28. The method of claim 26, wherein the conductor defines a gap along its entire length, to create two full-length top and bottom halves, to allow for differential thermal expansion.
- 29. The method of claim 26 wherein the insulator is in part accomplished by a space, to reduce the component capacitance.
- 30. The method of claim 25 comprising two conductors, to accomplish a transformer.
- 31. The method of claim 25 comprising three conductors, to accomplish a differential current transformer.
- 32. The method of claim 25 comprising more than two conductors to accomplish a step up or step down transformer with a desired voltage transformation from the input or inputs to the output or outputs.
- 33. The method of claim 25 wherein the magnetic core and all conductors meander through a plurality of turns, to increase the component's effective length.
- 34. The method of claim 25, wherein the magnetic core comprises a plurality of laminations separated by non-magnetic insulating material, each lamination completely surrounding all of the conductors.
- 35. The method of claim 25, wherein at least one conductor defines a gap along its entire length, to define two full-length top and bottom halves, to allow for differential thermal expansion.
- 36. A method of fabricating an elongated, planar, generally linear electrical inductor by multi-layered fabrication, the inductor having a single conductor, a magnetic core co-linear with the conductor along the entire component length, and completely surrounding the conductor, and an insulator separating the conductor from the magnetic core, the method comprising:
a. fabricating two component halves, each half made by: providing a lower layer of magnetic core material; providing spaced vertical segments of the magnetic core, in contact with the lower layer of magnetic core material; providing a bottom insulator layer on top of the lower layer of magnetic core material and the spaced vertical segments; providing the conductor on top of the insulator; and planarizing the top surface of the construction; and b. mechanically and magnetically coupling together the planarized surfaces of the two halves, to complete the component.
- 37. The method of claim 36, wherein the magnetic core defines a magnetic circuit comprising a gap.
- 38. The method of claim 36, wherein the conductor defines a gap along its entire length, to create two full-length top and bottom halves, to allow for differential thermal expansion.
- 39. The method of claim 36 wherein the insulator is in part accomplished by a space, to reduce the component capacitance.
- 40. The method of claim 36 wherein the magnetic circuit and all conductors meander through a plurality of turns, to increase the component's effective length.
- 41. The method of claim 40, wherein the magnetic circuit comprises a plurality of laminations separated by non-magnetic insulating material, each lamination completely surrounding all of the conductors.
- 42. The method of claim 36, wherein the conductor defines a gap along its entire length, to define two full-length top and bottom halves, to allow for differential thermal expansion.
- 43. A method of fabricating an elongated, planar, generally linear electrical inductor by multi-layered fabrication, the inductor having a single conductor, a magnetic core co-linear with the conductor along the entire component length, and completely surrounding the conductor, and an insulator separating the conductor from the magnetic core, the method comprising:
providing an elongated conductive wire having an essentially circular cross-section; coating the wire with a non-magnetic insulation layer; and coating the non-magnetic insulation layer with a first layer of magnetic core material.
- 44. The method of claim 43, further comprising creating a plurality of laminations in the magnetic core by sequentially coating the first layer of magnetic core material with one or more laminations, each comprising a coating of non-magnetic insulating material and then a coating of magnetic core material on top of the coating of non-magnetic insulating material.
- 45. The component of claim 9, wherein the component comprises two or more stacked layers of meanders, to increase the conductor and core length.
- 46. The component of claim 1, wherein the component directly connects between two spaced components in an electrical circuit, to both accomplish a desired inductance as well as carry current between the two spaced components.
- 47. A multiple inductive component inductive circuit comprising a plurality of inductive components of claim 1 connected in a desired series and/or parallel circuit combination, to achieve a desired inductance value or voltage conversion.
CROSS REFERENCED TO RELATED APPLICATION
[0001] This application is a continuation in part of application Ser. No. 09/257,068, filed on Feb. 24, 1999, U.S. Pat. No. 6,233,834. Priority is claimed.
STATEMENT OF FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
[0002] This invention was made with Government support under contract number DTRA01-99-C-0186 awarded by BMDO. The Government has certain rights in the invention.
Continuation in Parts (1)
|
Number |
Date |
Country |
Parent |
09257068 |
Feb 1999 |
US |
Child |
09861736 |
May 2001 |
US |